Fuel transducer module protective cover

ABSTRACT

A fuel sending unit protective cover assembly is disclosed, for protecting the fuel transducer module mounted to a fuel tank. The protective cover is associated with a locking ring. The locking ring engages the E-ring permanently secured to a fuel tank, by rotational engagement of the locking ring with one or more tabs protruding from the E-ring. The cover body with a plurality of descending legs is configured to engage ascending legs on the E-ring. The cover body is configured to permit installation and removal of the protective cover from the fuel tank without removal or disconnection of fluid conduits and electrical wiring.

FIELD OF THE INVENTION

The present invention relates in general to a device for securing andprotecting a fuel transducer module in relation to a fuel tank.

BACKGROUND

A fuel transducer module is a common element in a fuel storage vessel,such as a fuel tank utilized in a vehicle. A fuel tank is a vesselhaving at least one filler opening and at least one outlet. Because thefuel tank is often mounted deep within the structure of a vehicle, andhence, not readily accessible or visible to the operator, a fuel levelsensing unit or transducer is typically installed in the tank totransmit, electrically or mechanically, an indication of the quantity offuel remaining in the tank.

Because each opening in the fuel tank presents the opportunity forspillage or leakage, it is desirable to minimize the number of openingstherein, and accordingly, fuel tank designs may utilize a unifiedtransducer module which includes conduits for fuel and fuel vapors. Themodule fits over or within an opening in the tank, and is secured to thetank by appropriate seals to prevent leakage.

In a typical mounting installation for a fuel transducer module, a “hardpoint” or anchor is permanently affixed to the tank. Typical of suchattachment points is an imbedded or encapsulated ring, commonly referredto as an “E-ring” which may be molded into a plastic tank or welded to ametal tank. Such an E-ring typically surrounds a circular opening in thetank, and the fuel transducer module is engaged therewith. To hold thefuel transducer module in position on the tank in relation to theE-ring, a locking ring is provided which engages the E-ring andtypically captures a flange on the fuel transducer module between thelocking ring and the surface of the fuel tank. Typical of suchinstallations is a fuel-sending unit and locking ring as described inU.S. Pat. No. 5,207,463, issued to Seizert, et al., and described inU.S. Patent Application Publication 2004/0021271, to Tratnik.

A typical fuel transducer module presents one or more electricalconnectors, usually in the form of an electrical union comprised of asocket and a plurality of conductors disposed in each. The transducermodule also typically contains one or more fuel conduits or vents whichcommunicate with the interior of the fuel tank.

In recent years, vehicle crashworthiness standards have evolved whichinclude regulations and engineering specifications designed to reducethe likelihood of fire or explosion in the event of a vehicularaccident. In particular, a great deal of attention has been paid to fueltank design, with due consideration to the positioning of the fuel tanksin vehicles, and the reduction of risk of damage to the fuel tank andits components in a collision.

Because elements of the fuel transducer protrude outward from thesurface of the fuel tank, it is desirable that those components beprotected from impact during a collision. As a result, guards have beendeveloped to surround the fuel transducer module, thereby offering ameasure of protection against damage to the components of the moduleduring a collision.

Existing guards utilize either a stamped or drawn construction. Theseguards have a plurality of openings which allow electrical wiring andtubing to be connected from the vehicle in which the fuel tank ismounted to the fuel transducer module. The guards are typically mountedto the fuel tank or locking ring using threaded fasteners, such asstuds.

The design of currently known guards, however, presents certainpractical limitations during fuel tank assembly and repair operations.Attachment of a guard utilizing threaded fasteners is time-consuming,and the manufacture of locking rings containing threaded fasteners isexpensive. Additionally, currently known guards require the removal ofthe electrical connectors, fuel and vent lines from the transducerduring the assembly or repair process.

It is desirable, therefore, to provide a fuel-sending unit protectivecover which can be easily attached to and removed from the fuel tankwithout the need for fasteners or tools, which is simple to manufactureand affordable, and which simplifies vehicle assembly and repair bybeing installable and removable without disturbing the electrical, fluidand vent connections between a vehicle and its installed fuel tank.

It is an object of the present invention, to provide a protective guardto surround a fuel transducer module, and to protect said module againstdamage from external forces.

It is further an object of the present invention to provide a guardwhich is easily formed from a single piece of material.

It is a further object of the present invention to provide a guard whichis easily and securely attached to a fuel tank and fuel transducermounting ring without the need for fasteners, such as nuts, bolts orstuds, and which can be affixed to a fuel tank without the use ofnumerous tools.

It is a further object of the present invention to provide a guard for afuel transducer module which is easily installed and removed from a fueltank, while allowing the fuel transducer module to remain in place, andwithout requiring disconnection of conduits or electrical wiringharnesses from the transducer.

SUMMARY

A fuel-sending unit protective cover is provided for protecting a fueltransducer module mounted to a fuel tank. The protective cover isassociated with a locking ring. The locking ring engages the E-ringpermanently secured to a fuel tank, by rotational engagement of thelocking ring with one or more tabs protruding from the E-ring. Aplurality of slots is provided on the locking ring to engage the tabs ofthe E-ring, and a fuel transducer module is captured between the surfaceof the fuel tank and the E-ring.

A cover body with a plurality of descending legs is configured to engageascending legs on the E-ring. The distal ends of the descending legs areprovided with feet, which, in turn, engage spring clips mounted to theascending legs of the locking ring. The body of the cover is providedwith a socket for engagement with an installation and removal tool.

The feet of the cover engage detents in the spring clips preventingunintentional rotation of the cover in relation to the E-ring. The coverand its associated legs are configured so that the legs do not interferewith the fuel transducer module when the cover is installed or removed.

BRIEF DESCRIPTION OF THE DRAWINGS

The description herein makes reference to the accompanying drawingswherein like reference numerals refer to like parts throughout theseveral views, and wherein:

FIG. 1 is a perspective view of a fuel transducer module associated witha locking ring, as taught in the prior art.

FIG. 2 is a side view of the present invention in engagement with alocking ring, as positioned on a fuel tank.

FIG. 3 is a perspective view of the surface of a fuel tank to which isattached a conventional E-ring.

FIG. 4 is a perspective view of the present invention in partialengagement with the locking ring of the present invention.

FIG. 5 is a perspective view of the protective cover and locking ring ofthe present invention in substantial engagement.

FIG. 5A is a detailed view of a first portion of the locking ringengaged with the protective cover.

FIG. 5B is a detailed view of a second portion of the locking ringengaged with the protective cover.

DETAILED DESCRIPTION

The environment in which the invention operates is depicted generally atFIG. 1. A fuel tank 12, typically constructed of either metal orplastic, is formed in the configuration of a generally closed vesselhaving a top, bottom, and sides. As depicted in FIG. 1, an attachmentarea 14 it is designated on one surface of the fuel tank 12 (usually atop surface) onto which a fuel transducer module 20 will be mounted.Typically, this area 14 of the fuel tank 12 is substantially flat andsmooth. An opening is formed in the fuel tank 12 to accommodate portionsof the fuel transducer module 20 including associated conduits 22 andfuel-level measuring elements (not shown). The transducer module 20 isalso typically equipped with an electrical union 24 in the form of asocket equipped with a plurality of electrical conductors, designed toengage with a mating electrical plug (not shown). The transducer module20 contains multiple conduits 22 for transmission of fuel, air and fuelvapors to and from the interior of the fuel tank 12. All of the conduits22 and electrical unions 24 are mounted to a unitary body, and theentire transducer module 20 is typically pre-manufactured andappropriately configured for the particular fuel tank installation ofthe type common to motor vehicles. It will be appreciated that fueltransducer modules 20 of this type are designed to be fullypre-assembled prior to installation on the fuel tank 12.

The fuel transducer module 20 body is typically cylindrical, having thenecessary strength and thickness to provide sufficient mechanicalsupport to the conduits 22 and electrical union 24 mounted to the uppersurface of the module 20, as well as to the conduits 22 and transducerelements mounted to and through the bottom of the transducer module 20.

With further reference now to FIG. 1, FIG. 2 and FIG. 3, the placementof the fuel transducer module 20 in relation to the fuel tank 12 will bebest understood. To facilitate attachment, the fuel tank 12 is providedwith an attached or embedded ring 40, commonly referred to as an E-ring,and typically manufactured of metal appropriately formed and stamped.The E-ring 40 has an annular body 44, and protruding therefrom at aplurality of locations around the circumference of the E-ring 40 is aseries of tabs 46. Each tab 46 has an upwardly extending ascender 48,and a horizontal extension 50 which extends inwardly toward the centerof the E-ring 40 substantially parallel to the upper surface of fueltank 12. Although FIG. 2 and FIG. 3 depict an E-ring 40 of the typegenerally embedded within a molded plastic tank, it will be appreciatedthat E-ring 40 can be mounted to the upper surface of the tank 12 aswell. For attachment of E-rings 40 to metal tanks, it is known toutilize fasteners or welding to secure the E-ring 40 to the tank 12,where it functions in substantially the same fashion as an E-ring 40which is embedded in a molded plastic tank 12. The E-ring 40 soconfigured and attached creates the basic point of attachment for thefuel transducer module 20, when used in conjunction with an appropriatelocking ring.

A locking ring 60 of the type utilized in the present invention isdepicted in FIGS. 2, 4, 5 and in detail in FIGS. 5A and 5B. The lockingring 60 comprises an annular body having a central aperture 64. Theouter circumference of the central aperture 64 is turned upward,creating a lip 66. The lip 66 is provided with a plurality of plateaus67 and ramp sections 65 which extend upward from the annular bodyportion at a height above the height of the remaining circumferentiallip 66. Also extending upward from the circumferential lip 66 is aplurality of feet 70 a-c, each comprising an ascender 68, a toe portion72, a heel portion 71 and a slot 74. The plurality of slots 74associated with said plurality of ascenders 68 are open in the samecircumferential orientation as shown in FIG. 4, to allow insertion of acover element which will be described in detail herein.

The body of the locking ring 60 is further provided with a plurality ofarcurate openings 80, each said arcurate opening 80 having a wideportion 82 and a narrow portion 84. The width of the wide portion 82 ofeach said arcurate opening 80 corresponds to the width of the tabextension 50 of the E-ring tab 46, so that the locking ring 60 may fitover the tab extensions 50 when the locking ring 60 wide portion 82 ofthe arcurate opening 80 is aligned with the tab extension 50 of theE-ring tabs 46. As depicted in FIG. 2, once the locking ring 60 has beenplaced over the E-ring tabs 46, it will rest substantially on the uppersurface of the transducer 20 and of the fuel tank 12. In thisembodiment, a gasket 38, preferably in the form of an O-ring, is placedbetween the annular body of the locking ring 60 and the upper surface ofthe fuel tank 12, so as to be positioned between the bottom of the fueltransducer module 20 and the upper surface of the fuel tank 12, therebycreating a fluid-tight seal between said fuel transducer module 20 andsaid fuel tank 12.

The fuel transducer module 20 body is formed with an annular lip 29having a diameter larger than the diameter of the central aperture 64 ofthe locking ring 60. Accordingly, placement of the locking ring 60 overthe module 20, and over the E-ring tabs 46 establishes the initialposition for securing the fuel transducer module 20 to the upper surfaceof the fuel tank 12. In this configuration, the locking ring 60 is readyfor rotation in the direction R.

From FIGS. 2, 3 and 4, it will be appreciated that the annular body ofthe locking ring 60, adjacent to the narrow portion 84 of the arcurateopenings 80, is provided with a plurality of protrusions 86. As thelocking ring is rotated in direction R, the ascenders 48 of the tabs 46of the E-ring 40 pass into the narrow portion 84 of the arcurateopenings 80 of the locking ring, and at the same time tab extensions 50engage the protrusions 86 of the locking ring 60. The height of theascenders 48 of the tabs 46 of the E-ring 40 is selected to result inengagement between the tab extensions 50 of the E-ring 40 with theprotrusions 86 adjacent the arcurate openings 80 of the locking ring 60.This engagement urges the locking ring 60 downward, toward the E-ring40, with the annular lip 29 of the fuel transducer module 20 capturedunder the annular body 62 of the locking ring 60, and simultaneouslycompressing the gasket 38 between the annular lip of the fuel transducermodule and the upper surface of the tank 12. Detents 52 formed in thetab extensions 50 of the E-ring 40 frictionally engage the protrusions86 adjacent to the narrow portions 84 of the arcurate openings 80,preventing counter-rotation of the locking ring 60 in relation to theE-ring 40.

To facilitate the rotational engagement above described, the lockingring 60 is provided with a plurality of cutouts 76 around itscircumference which are designed to engage with a cooperativeinstallation tool (not shown). This tool is provided with a plurality ofengaging fingers and a central socket of the type adapted to engage asquare drive ratcheting wrench. By placement of the fingers of the toolin the cutouts 76 of the locking ring 60, and by application of torquein the direction R, the locking ring 60 can be rotated conveniently intothe locked configuration, after which the tool may be removed.

At this stage in the installation process, the transducer module 20 issecured to the mounting surface of the fuel tank 12 by the locking ring60 and its engagement with the E-ring 40. With reference now to FIGS. 2,4, 5, 5A and 5B, securement of the protective cover 100 of the presentinvention will be fully understood. The protective cover 100 comprises aformed element having a body 102 and a plurality of legs 104, each ofsaid legs 104 having formed therein a foot 106. In plan view, it will beappreciated that the legs 104 of the cover 100 are oriented as follows:two of the legs 104 are positioned substantially in diametricopposition, with a third leg 104 positioned approximately at an angle ofapproximately 60° (ø₁) to a first one of the legs 104, and at an angleof approximately 120° (ø₂) to a second one of said first legs 104. Thisconfiguration leaves a substantially semi-circular opening (ø₃)unimpeded, thereby allowing installation of the cover 100 even thoughthe fuel transducer module 20 and its conduit and wiring already inplace and connected. The cover 100 with its associated body 102 and legs104, provides protection to the fuel transducer module 20 in the eventof a catastrophic impact to the fuel tank area surrounding the module.Each leg 104 of the cover is formed at its proximal end as a portion ofthe body 102, and is bent substantially normal to the body 102, therebycreating a descending leg 104 element to engage the locking ring 60. Atthe distal end of each leg 104 is formed a foot 106 having a heel 108and a guide 110 designed to engage the locking ring 60 in a manner to bedescribed. Ridges 87 are formed in feet 106 to engage spring elements 79a-c as herein described.

Each foot 70 a-c of the locking ring 60 has a heel 71, a toe 72 and aslot 74. Affixed between the heel 71 and the toe 72 are clips 77 a-c,utilizing fasteners 69, such as rivets. The clips 77 a-c are formed of aresilient material, such as spring steel. The clips 77 a-c each have aspring element 79 a-c formed therein. One end of each spring element 79a-c is provided with a V-shaped detent 75. Impressed within one surfaceof the V-shaped detent 75 c is an impression 88. This impression engagesa gap 78 formed in foot 106. At the distal end of each spring clip 77a-c an upward turned tang 73 is provided to allow engagement of a toolto lift the spring element 79 a, if necessary for removal of the cover.

Complimentary to the locking ring feet 70 a-c are cover element feet106, each of which is provided with a ridge 87 and a guide 110. Theguide 110 is oriented downwardly, and is configured to engage the outercircumference of the lip 66 of the locking ring 60. The guides 110,collectively, therefore, serve to guide and position the cover intojuxtaposition with the locking ring 60. Each foot 106 has a ridge 87formed therein. As shown in FIG. 5A, at least one of the foot 106associated with at least one leg 104 of the cover 100 is provided with agap 89 formed in ridge 87. This gap 89 engages the impression 88 formedin the spring element 79 a of the clip 77 a, effectively locking thespring element 79 into the upturned portion of the ridge 87.

To install the cover 100 in relation to the locking ring 60, the cover100 is placed on the locking ring 60 so that the undersides of the feet106 rest on the upturned lip 66 of the annular body of the locking ring60, with the feet 106 of the cover adjacent to the feet 70 of thelocking ring 60. The cover is then rotated in direction R, bringing thefeet 106 of the cover into the slots 74 of the locking ring feet 70.This rotation also brings the feet 106 of the cover into engagement withthe spring elements 79 of the clips 77. Further rotation of the cover100 in direction R brings the detents 75 of the spring elements 79 intoengagement with ridges 87 on the cover feet 106. Simultaneously, theguides 110 of the cover feet 106 serve to guide and position the cover102 into alignment with the lip 66 of the locking ring 60. Once fullyengaged, the detent of the spring elements 79 locks the cover 100 intothe desired positional relationship with the locking ring 60.

In one embodiment, the upper section of the protective cover is providedwith a socket 120 configured to engage a typical square driveratchet-type wrench to allow the cover 100 to be rotated into lockedrelationship with the locking ring 60 by providing the necessarymechanical advantage to impart the necessary torque to the cover 100.

By virtue of the angular relationship of the legs of the cover 100, thecover 100 can be installed on and removed from the locking ring 60without the necessity of disconnecting any of the electrical or fluidconnections associated with the fuel transducer module 20.

The foregoing description of the preferred embodiment according to thepresent invention are provided for the purposes of illustration only,and not for purposes of limitation, the invention being defined by theclaims:

1. In a fuel tank equipped with an embedded mounting ring for securing atransducer to said tank, a fuel transducer module protective coverassembly comprising: a locking ring removably engageable with saidmounting ring, said locking ring comprising a plurality of slotsoriented in a common circumferential direction in relation to thecircumference of said ring; a plurality of spring clips adjacent to saidslots; and a cover element comprising a body portion and a plurality oflegs dependent from said body portion, each of said legs having a footelement dependent therefrom, whereby one of each said foot elements isengageable with one of each said slots, and whereby said cover elementand said locking ring are secured in engagement by said spring clips. 2.The invention of claim 1, wherein said plurality of legs furthercomprises a first leg, a second leg and a third leg, said first and saidsecond legs being substantially diametrically opposed on said body andsaid third leg disposed on said body between said first and said secondlegs.
 3. The invention of claim 2, wherein said body further comprises asocket whereby an engaging tool is removably attachable to said coverelement.
 4. The invention of claim 1, wherein at least one of said footelements comprises a ridge, wherein said at least one of said springclips comprises a detent, and wherein said ridge engages said detentwhen said cover element is engaged with said locking ring.
 5. A coverfor attachment to an annular fuel transducer locking ring having a firstcircumference, said cover comprising a substantially circular body and asubstantially cylindrical side wall having a second circumference and asubstantially circular lower edge, further comprising at least oneopening formed in at least one section of said side wall, said openingextending through said edge.
 6. The invention of claim 5, furthercomprising attachment means for removably securing said cover to saidlocking ring.
 7. The invention of claim 6, wherein said attachment meansare spring clips engaging said lower edge and said locking ringcircumference.